Composite Armor Element, And Effective Body Element for Insertion in a Composite Armor Element

ABSTRACT

A composite armor element for protection against projectiles. At least one layer of effective bodies is disposed in rows next to one another in the composite armor element, the effective bodies being embedded in a matrix material. The effective bodies of one row are fixedly interconnected at least partially by means of webs to form a chain which is a monolithic element. An effective body element for insertion in a composite armor element comprises at least two effective bodies fixedly interconnected by at least one web to form a chain. The effective body element is a monolithic element, and a plurality of effective body elements are embedded in a matrix material.

The present invention relates to a composite armor element for protection against projectiles or missiles having the features from the introductory portion of patent claim 1, as well as an effective body element for insertion in a composite armor element having the features form the introductory portion of patent claim 34.

Composite armor elements, such a composite armor plates or composite armor mats, which are comprised of a composite of several materials, are known. Frequently, composite armor elements are constructed in such a way that filler material or active or effective bodies are introduced between two, for example plate-shaped, elements, with a matrix material that is capable of being cast, for example polymeric materials or metals, subsequently being cast about the effective bodies.

The plates are frequently provided with end layers. The manufactured composite armor pates can have thick composite fiber layers glued to their back side, thus forming self-supporting armor elements, or they can be applied to metallic vehicle housings, such as a welded steel pan, whereby they achieve the complete protection effect together with the housing structure. It is additionally known to dispose shock-dampening materials between the effective bodies so that the effective bodies do not rest directly against one another in a disadvantageous manner.

DE 1 578 324 describes a composite armor plate, whereby individual balls or cylinders made of a hard ceramic material are utilized as active or effective bodies. The cylinders are disposed in rows in the plate in a plurality of uninterrupted layers or plies, i.e. their longitudinal axes are disposed essentially parallel to the plane of the plate and parallel to one another, whereby the cylinders of one layer are offset relative to the cylinders of the other layer. The cylinders are furthermore spaced from one another, whereby a plurality of layers of a spacing material are used in such a way that each layer of spacing material is alternatingly wound above or below the cylinders in their pertaining layer.

EP 1 071 916 B1 describes a composite armor plate having individual cylindrical ceramic effective bodies, whereby the space between the effective bodies is filled with triangular or hexagonal intermediate space pellets that are adapted to the shape.

EP 1 363 101 A1 describes a composite armor plate, whereby the individual active bodies are provided with a band to reduce the overall weight of the plate.

The drawback of the known plates is that the manufacture is expensive and imprecise due to the large number of the small effective bodes as well as the insertion of shock-dampening materials.

It is an object of the present invention to improve the aforementioned drawbacks. The invention realizes the object with the features from the characterizing portion of patent claim 1 as well as with the features from the characterizing portion of patent claim 34. Advantageous further developments are the subject matter of the dependent claims.

It is a basic concept of the present invention to connect the effective bodies via, in particular, short and narrow webs to form long rows, and thus to provided easy-to-manufacture effective body elements, designated as effective body chains. Within the framework of the manufacture of the composite armor element, these are easier to handle, since due to the reduction of the number of parts considerably fewer operating steps are required. In addition, it is no longer necessary to introduce shock-dampening materials between the effective bodies, since the webs ensure a minimal gap between the effective bodies and hence a shock-dampening by means of the webs or the matrix material in the gaps between the effective bodies is effected.

The individual effective bodies of an effective body element can be produced from extra hard materials, in particular ceramic, metallic, sintered or fiber materials, with relative to the plate dimensions smaller dimensions. They can be cylindrical, spherical or tetrahedral, or can have a rod-shaped configuration with a polygonal cross-section. The end faces can be linear, convex, conical, angular, or inclined. The effective bodies preferably have at least in part a ratio between height and maximum width extension that is greater than 0.8. The effective bodies are preferably oriented parallel to one another. Furthermore, an upright arrangement of the effective bodies in the composite armor element is preferred, whereby, however, a horizontal or an inclined arrangement is also usable. The effective bodies of one layer can be offset relative to the effective bodies of an adjacent layer. In the same manner, the effective bodies of one row can be offset relative to the effective bodies of an adjacent row.

The webs have prescribed dimensions, whereby the extension in the radial direction relative to a rod-shaped or cylindrical effective body is designated as the web length. The extension of the web in an axial direction is designated as the web height. The extension that lies in a direction tangential to the outer surface of a cylindrical effective body is designated as the web width.

Two or more webs can also be used between two effective bodies. In this way, the stability of the effective bodies can be improved, thus reducing the risks that the chains unintentionally break during manufacture, transport or processing.

As a consequence of the joining together of the effective bodies by means of webs, chain-like effective body elements result that contain a plurality of individual effective bodies. Relative to the main dimensions of the effective bodies, the webs can have a lesser length and/or a lesser width, i.e. can be short and/or narrow. The web height can be in the range of the height of the effective bodies. The number of connected effective bodies can vary as desired, and is preferably in the range of 5-20. The webs should have an adequate stability in order to enable a reliable handling during manufacture. On the other hand, it can be advantageous to embody the webs in such a way that during the manufacture of a composite armor element, the chain can be broken or divided manually or with a machine in order to obtain the correct length. Pursuant to one preferred embodiment, the ratio of the minimum web width to the maximum main dimension of the effective body cross-section is less than 0.4. Furthermore, the web can be provided with a break notch, so that during the placement of the effective body chains in the composite armor element, shorter effective body chains can be broken off, for example if this is necessary at the edge of the composite armor element (“Toblerone-principle”). In this way, the manufacture can be simplified.

The geometry of the webs can be linear or can have a rounded-off portion; furthermore, a notch can be provided on one side or on several sides. The notch width can extend over the entire web length, and the notch angle can be in the range of between 40° and 100°. Furthermore, the ratio of the web width at the notch base and the web length can be in the range of from 0.3 to 2.5.

The webs can be comprised of polymeric materials, in particular elastomers, or of soft metals. They are fixedly connected with the effective bodies, and can be provided with adhesive compounds or can be formed entirely or partially as an integral part of effective bodies. Pursuant to one particularly advantageous embodiment of the invention, the effective body chains are manufactured monolithically, i.e. as a single piece, so that rigid, “standard formed” effective body chains result. Thus, no individual effective bodies are any longer produced; rather, entire effective body chains are produced in a single operation, with the webs being comprised of the same material as the effective body. In this connection, the shock-dampening is realized by the described formation of the web regions.

If the composite armor element is struck by an armor-piercing hardened-core projectile, the projectile core is broken up and destroyed upon striking a very hard effective body. In so doing, the struck effective body is also entirely destroyed, and the end layer or also the wall of the vehicle structure absorbs the remainder of the impulse, so that no penetration into the interior space that is to be protected takes place. Due to the high local energy entry, pronounced shock waves occur with this process that where the adjacent effective body rests directly upon the struck body are transmitted to this adjacent effective body and also destroy it, even though it was not struck directly. This would be transferred to further adjoining effective bodies, and a larger damaged region would result that would no longer be safe for a subsequent round or strike. The inventive webs dampen the transfer of the shock waves by use of the described materials or by the use of the described configuration of the thin webs or the provision of special notches. The radii of destruction when a direct hit occurs are thus minimized, and a good “multi-hit-capability” results; in other words, the protective function is maintained even after a number of closely spaced together, successive direct hits.

The chain-like effective body elements can be placed in straight rows within one layer in the composite armor plate. However, they can also be zig-zag shaped or looped. Multi-row effective body matrices can also be used that in particular can be monolithically produced and that can be divided as desired during the manufacture of the composite armor element.

After the assembly process, the arrangement of the effective body chains is embedded into the matrix material, in particular polymeric materials such as polyurethane, epoxy resin, polyester or rubber, and can be closed off on the front side by means of a protective layer. The other side can be comprised of layers produced of materials having shock-absorbing properties, whereby in addition a high tensile strength should exist. The composite armor element can be mounted in a self-supporting manner in a frame construction, or can be mounted on a structure housing of armored steel or light metal, whereby an intermediate air layer or shock-absorbing intermediate layers can be provided.

The invention is not limited to using only identical geometries and materials within a composite armor element. Rather, the invention also includes combinations of the described materials and geometries.

A particularly straightforward manufacture can be achieved if during the manufacture the chain-like effective body elements are placed in a case that is produced in particular in an accurately dimensioned manner and of steel, light metal, polymeric material or fiber composite material, and is then cast or vulcanized with a matrix material. In this situation, the case becomes an integral part of the protection module, and can represent the outer layer or boundary thereof. The effective body chains can also be placed in an in particular accurately dimensioned manufacturing mold or in a manufacturing molding box, and can then be cast or vulcanized with the matrix material.

Embodiments of the invention are described with the aid of FIGS. 1 to 9, which show:

FIG. 1 a a chain-like effective body element in an isometric illustration;

FIG. 1 b the effective body element of FIG. 1 a from a different perspective;

FIG. 2: the effective body element of FIG. 1 with altered end faces;

FIG. 3 a plan view onto the effective body element of FIG. 2;

FIG. 4 a further embodiment of an effective body element;

FIG. 5 a portion of the effective body element of FIG. 3;

FIG. 6 a modified embodiment of the portion of FIG. 5;

FIG. 7 effective body elements according to FIG. 1 combined to form an effective body matrix;

FIG. 8 a composite armor plate with the effective matrix of FIG. 7 disposed in a case;

FIG. 9 a cross-section of a composite armor plate placed upon a housing of a combat vehicle.

FIGS. 1 a and 1 b show an active or effective body chain 1 as an active or effective body element, which is composed of individual ceramic active or effective bodies 2 a having the same geometry; these effective bodies are rigidly or fixedly interconnected by means of linear webs oe fins 3. The effective body chain 1 is manufactured monolithically, i.e. as a single piece, so that the webs 3 are comprised of the same material as are the effective bodies 2 a. The effective bodies 2 a, which have a height h, have a cylindrical fundamental shape with an essentially circular cross-section having the diameter b. The end faces are embodied as cones 4 a having rounded apexes. FIG. 2 illustrates an effective body chain with which the end faces are curved or bulged convexly outwardly.

As a consequence of the webs 3, a prescribed spacing exists between the individual effective bodies 2 a. As can be seen in FIG. 3, the essentially circular cross-section is provided in the region of the web 3 with a side cut or cutout 5. The configuration of the effective body chain is such that the center points of the identical circular cross-sectional surfaces are spaced apart exactly by a distance that corresponds to the radius of the circle. In other words, in the region of the webs 3 the effective bodies have cutouts 5 that correspond to half of the web width.

The webs 3 have a constant web width E and web length D, which have approximately the same dimensions and are significantly less than the web height F. It can furthermore be seen that the ratio of the minimum web width E to the maximum main diameter of the effective body cross-section b is less than 0.4.

FIG. 4 shows an effective body chain 1 according to which the individual effective bodies 2 b have a hexagonal cross-sectional sectional surface. The end faces 4 c have a pyramid-shaped configuration.

FIG. 5 shows that the webs 3 a are provided with two notches 6 a so that during the manufacture the effective body chain can be broken or divided. Pursuant to FIG. 6, the notches 6 b, having the notch base radius B, can, at a prescribed notch angle A, also extend over the entire web length D, whereby the ratio of the notch base web width C and the web length D ranges from 0.3 to 2.5.

FIG. 7 shows a monolithically produced effective body matrix 7, according to which the effective bodies 2 a are interconnected by means of webs 3. Each effective body 2 a is connected with other effective bodies 2 a via six webs 3. The webs 3 have the previously described break notches 6. The effective bodies 2 a, which are provided with conical end faces 4 a, are additionally disposed in such a way as to be offset relative to one another.

FIG. 8 shows the arrangement of the effective body matrix 7 in a metal case 8. The case 8 represents the outer protective layer of a composite armor plate, and is cast or adhesively joined to the effective body matrix 7 and a lower end layer 9 of fiber material via a non-illustrated matrix material.

FIG. 9 shows the arrangement of a composite armor plate as a composite armor element on a metallic housing 12 of an armored combat vehicle. The plate is comprised of the case 8, a matrix material 13 in the form of a casting or adhesive mass, a layer of the extra hard effective body chains 2, and the end layer 9. Disposed between the end layer 9 and vehicle 12 is a dampening elastomer intermediate layer 11. 

1-44. (canceled)
 45. A composite armor element for protection against projectiles, comprising: at least one layer of effective bodies, wherein said effective bodies are disposed in rows next to one another in said composite armor element, further wherein said effective bodies are embedded in a matrix material, further wherein said effective bodies of a given row of effective bodies are fixedly interconnected at least partially by means of respective webs to form a chain, and wherein said chains of said effective bodies are respective monolithic elements.
 46. A composite armor element according to claim 45, wherein said effective bodies of a given layer in adjacent rows are fixedly interconnected in a matrix-like manner at least partially by webs.
 47. A composite armor element according to claim 45, wherein said effective bodies are at least partially cylindrical with a circular or oval cross-section.
 48. A composite armor element according to claim 47, wherein at least one of the end faces of said effective bodies has a conical configuration, in particular with a rounded apex.
 49. A composite armor element according to claim 45, wherein said effective bodies have an at least partially spherical configuration.
 50. A composite armor element according to claim 45, wherein said effective bodies are at least partially rod-shaped with a polygonal cross-section.
 51. A composite armor element according to claim 50, wherein at least one of the end faces of said effective bodies has a pyramidal configuration, in particular with a rounded apex.
 52. A composite armor element according to claim 45, wherein at least one of the end faces of the effective bodies has a concave or convex configuration.
 53. A composite armor element according claim 45, wherein said effective bodies are provided at least partially with linearly or transversely sectioned end faces.
 54. A composite armor element according to claim 45, wherein said effective bodies at least partially have a ratio between height of said effective bodies and maximum width dimension of said effective bodies that is greater than 0.8.
 55. A composite armor element according to claim 45, wherein a ratio of a minimum web width to a maximum main dimension of a cross-section of said effective bodies is less than 0.4.
 56. A composite armor element according to claim 45, wherein said webs are at least partially provided with a notch.
 57. A composite armor element according to claim 56, wherein said notches extend over the entire web length.
 58. A composite armor element according to claim 56, wherein said notches form a notch angel that is in the range of 40° to 100°.
 59. A composite armor element according to claim 56, wherein a ratio of a web width at the base of the notches and web length is in the range of from 0.3 to 2.5.
 60. A composite armor element according to claim 56, wherein said effective bodies are provide at least partially in the region of the web connections with cutouts that correspond to half of the web length.
 61. A composite armor element according to claim 45, wherein shock-dampening material, in particular metals, polymeric materials, elastomers, or fiber materials, are disposed between said effective body chains or effective body matrices, and wherein said shock-shock-dampening materials are in particular introduced in the form of thin sheets, fabric, filaments or granular material.
 62. A composite armor element according to claim 45, wherein effective body chains or effective body matrices are provided entirely or partially with at least one coating, in particular of metals, polymeric materials, elastomers, or fiber materials.
 63. A composite armor element according claim 45, wherein one side of said composite armor element includes at least one layer made of a fiber material, in particular aramid, glass fiber, polyamide or carbon fiber.
 64. A composite armor element according to claim 45, wherein one side of said composite armor element includes at least one layer made of a shock-absorbing material, in particular of foam materials or elastomers.
 65. A composite armor element according to claim 45, wherein said effective bodies are comprised at least partially of ceramic materials, in particular at least partially of aluminum oxide ceramic having an Al₂O₃ content of 92%-99.99%.
 66. A composite armor element according to claim 45, wherein said effective bodies are comprised at least partially of boron carbide, silicon carbide, silicon nitrite, or titaniumtriborate, or at least partially of sintered materials or of metallic materials, in particular hardened steel, aluminum or titanium.
 67. A composite armor element according to claim 45, wherein said matrix material is comprised of at least one polymeric material, in particular polyurethane, epoxy resin, polyester, rubber, or other elastomers.
 68. A composite armor element according to claim 45, wherein said matrix material (13) is connected to at least one continuous outer end layer.
 69. A composite armor element according to claim 45, wherein said effective bodies or said matrix material form an end of said composite armor element.
 70. A composite armor element according to claim 45, wherein said effective bodies are disposed parallel to one another.
 71. A composite armor element according to claim 45, wherein said effective bodies are disposed upright, inclined, or horizontally.
 72. A composite armor element according to claim 45, which is provided with at least two layers, wherein said effective bodies of the respective layers are disposed at least partially offset relative to one another.
 73. A composite armor element according to claim 45, wherein said effective bodies within a given layer of effective bodies are disposed at least partially offset to effective bodies in adjacent rows.
 74. A composite armor element according to claim 45, which includes a case, in particular of steel, light metal, polymeric material or fiber composite material, wherein said effective bodies are disposed within said case, and wherein said case in particular represents at least one end layer of said composite armor element.
 75. An effective body element (1) for insertion in a composite armor element, comprising: at least two effective bodies, wherein said effective bodies are respectively fixedly interconnected by at least one web to form a chain, further wherein said effective body element is a monolithic element, and wherein a plurality of effective body elements are embedded in a matrix material.
 76. An effective body element according to claim 75, wherein said effective bodies are fixedly interconnected by said webs to form a matrix.
 77. An effective body element according to claim 75, wherein a ratio of a minimum web width to a maximum main dimension of a cross-section of said effective bodies is less than 0.4.
 78. An effective body element according to claim 75, wherein said webs are provided at least partially with a notch.
 79. An effective body element according to claim 78, wherein said notch extends over the entire web length.
 80. An effective body element according to claim 78, wherein said notches form a notch angle that ranges from between 40° to 100°.
 81. An effective body element according to claim 78, wherein a ratio of a web width at a base of said notches and a web length ranges from 0.3 to 2.5.
 82. An effective body element according to claim 78, wherein said effective bodies are provided at least partially with cutouts in the region of the web connections, and wherein said cutouts correspond to half of a web length. 